Professional Documents
Culture Documents
User Manual
72.120.606/D
TABLE OF CONTENTS
1. INTRODUCTION
· The Fluenta Flare Gas Meter is the most robust and accurate flare meter on the
market today able to cover higher velocity ranges than any other flare meter. It
is an essential monitoring tool for E&P operators.
1982 – 1986.
The Fluenta Flaregas meter was developed by Christian Michelsen Institute
1985.
Christian Michelsen Institute founded Fluenta
AS
1987.
First Fluenta Flaregas meter in operation.
2001.
Roxar acquires Fluenta AS.
2007.
Roxar’s management board makes a
strategic decision to divest its flaring
business.
2009.
Fluenta is a worldwide organisation with offices in Paris, Dubai,
Malaysia, Houston and Bergen.
· The FGM 160 flow computer is field mounted and can be fully operated from
any location when connected via Modbus to the unique
software operator console.
Name : Fluenta AS
Org no: NO 991 199 098 MVA
Mailing address : PO Box 115 Midtun, 5828 Bergen, Norway
Visit address : Sandbrekkeveien 85, 5225 Nesttun, Norway
Invoicing address : P.O. Box 323, 5501 Haugesund
Phone : +47 55 29 38 85
Fax : +47 55 13 21 60
Web address : www.fluenta.com
Sales E-mail : sales@fluenta.com
Support E-mail : support@fluenta.com
2. SERVICE OFFERS
1. Local Capability
The Fluenta Support team has a wide network of service engineers and
technicians. All engineers are trained and certified according to our
internal training program, assuring our clients a fully competent and
professional assistance.
The use of the local engineers minimizes the mobilization time and takes
advantage of their knowledg e of local conditions and language.
2. Commissioning
The system shall be installed and commissioned as per the detailed
instructions in our Installation and Hook -Up Manual.
This work can be divided into several phases:
2.3 Commissioning
· Service Console software installation and configuration (if not already
pre- installed)
· Power- up checks
· Configuration and set -up of parameters
3. Service agreements
Fluenta recommends that commissioning and service are handled by
Fluenta qualified personnel through a mutual beneficial service program.
End user benefits for having signed a service agreement with Fluenta will
include:
3.3.1 Training
One of the critical success factors is the proper training of the personnel
directly involved with the equipment. This is also valid for technicians
and engineers using the data from it. The training program can be
designed to comply with customers requirements. Normally a
combination of practical “on -site” training on one of Fluenta’s training
spools and classroom training gives the best results. The objective of the
training program is to ensure that the technicians and engineers that are
to use the equipment will understand the principle behind the
technology, and that they will become able to operate the gear in an
ample way.
72.120.606/D Page 9 of 211
Service Offers
3.3.2 Maintenance
We recommend that Fluenta Metering Products are included in t he Clients
preventive maintenance program. Typical activities during check up are
calibration, evaluation of system performance and data validation.
The goal of the FGM 160 training courses is the technical introduction to
FGM 160, including operator consol e training and the usage of docklight.
The participants will be able to diagnose the system and make
conclusions of the proper actions for troubleshooting.
At the end of the course, the operator will possess technical knowledge
to perform troubleshooting a nd diagnostic, thus be able to provide
Fluenta with critical information in order to effectively introduce changes
to enhance overall system performance.
1. Operator course
1.1 Content
· Operator console
· Moxa communication hardware: Moxa Uport 1150/Moxa nport 1250
· DockLight license
1.3 Duration
2.1 Content
· Operator Console
· Moxa communication hardware (optional)
· Zero point calibration box
· Docklight License
· Extended course documentation and templates
2.3 Duration
3.1 Goal
3.2 Content
· Operator Console
· Moxa communication hardware
· Docklight License
3.4 Duration
· 1 day
3. MAIN DATA
1. Purpose ...................................................................................................... 15
2. Abbreviations/Definitions .............................................................................. 15
2.1 Abbreviations:.......................................................................................................................... 15
2.2 Definitions: .............................................................................................................................. 15
3. Utility Consumption Data............................................................................... 15
4. Nominal Power Consumption ......................................................................... 15
5. Maximum Power Consumption ....................................................................... 15
6. References .................................................................................................. 15
1. Purpose
This document gives the utility consumption requirements for the Fluenta Flare Gas
Meter, FGM 160.
2. Abbreviations/Definitions
2.1 Abbreviations:
FGM - Flare Gas Meter
2.2 Definitions:
N/A.
6. References
N/A.
1. Purpose
This document specifies the general, environmental, electrical and operational data of
the Fluenta Flare Gas Meter, FGM 160.
2. Abbreviations/Definitions
2.1 Abbreviations:
TFS Transducer Full Size
2.2 Definitions:
EEx-d/e FGM160 Field Computer Electronics Unit in EEx-d explosion proof enclosure
and connection housing in EEx-e enclosure.
3. General
Transducer
3.1 Ultrasonic / Time-of-flight / TFS / Wetted but non-intrusive
Type
Transducer
3.2 STANDARD OPTIONAL
Material
Titanium / Inconel
Titanium / Hastelloy
SS316 / Titanium
Titanium / 6Mo
Titanium / Duplex
ATEX: Nemko 07ATEX1160
CSA: CSA2241432 - Class I Div 2
3.3 Certification
GOST-R: 8468425
GOST-K: KZ7500361.01.01.16570
Field
Ex de [ia] IIC T6, Tamb: -40 °C to + 60 °C
Computer
Ultrasonic
Ex ia IIC T4-T6 (Zone 0)
Transducers
Flare Gas Measurement and other low pressure hydrocarbon gas
3.4 Service
flow measurements
4. Operating Limits
Operating
Temperature STANDARD OPTIONAL
(Transducers)
-94 to +293 °F (-70 to -166 to +428 °F (-110 to
+145 °C) *) +220 °C) **)
4.3 Operating Pressure 11.6 - 145 psiA (0.8 to 10 barA)
*)
: Lower temperatures than -70 °C for short period of times.
**): Pipe Sizes: 6” – 30”.
5. Design Limits
Design Temperature
5.1 STANDARD OPTIONAL
(Transducers)
-238 to +599 °F (-150 to -238 to +662 °F (-150 to
+315 °C) *) +350 °C) *)
5.2 Design Pressure 290 psiA (20 barA)*)
*)
: Mechanical survival ratings, NOT operational survival ratings.
6. Electrical Data
STANDARD OPTIONAL
6 x analog 4-20 mA outputs
HART output Foundation Fieldbus
6.4 Output Signal
Pulse / frequency signal TCP/IP via Ethernet
RS422 / RS485, 2- or 4- SoftFlow
wire Modbus Protocol, RTU
7. Functional Characteristics
7.1 Flow Velocity Range 0.1 - 394 ft/s (0.03 - 120 m/s)
STANDARD OPTIONAL
7.2 Accuracy
+/- 2.5% to 5% +/- 1% to 2%
7.3 Resolution 0.003 ft/s (0.0008 m/s)
Better than 1% of volume flow for velocity 0.3 - 100 m/s
7.4 Repeatability
(1 - 328 ft/s)
7.5 Turn Down Ratio 4000:1
7.6 Calibration Zero flow calibration*
Standard and actual volume flow, mass flow, totalized
Measurement standard volume flow, totalized mass flow, molecular
Parameters weight, standard density, actual density, pressure,
temperature, speed of sound, gas velocity
* Wet (flow) calibration on third-party rig for improved measurement accuracy can be offered.
8. Measuring Section
9. Field Computer
11. References
N/A.
1. Purpose ...................................................................................................... 23
2. Abbreviations/Definitions .............................................................................. 23
2.1 Abbreviations:.......................................................................................................................... 23
2.2 Definitions: .............................................................................................................................. 23
3. Weight Data Sheet ....................................................................................... 23
3.1 Transducer Full Size (TFS) Weight Data Sheet ......................................................................... 23
4. References .................................................................................................. 23
1. Purpose
This document specifies the weight of the components included in the Fluenta Flare
Gas Meter, FGM 160.
2. Abbreviations/Definitions
2.1 Abbreviations:
FGM 160 Fluenta Flare Gas Meter, model FGM 160
TFS Transducer Full Size
2.2 Definitions:
EEx-d/e FGM 160 in EEx-d explosion proof enclosure and connection housing in
EEx-e enclosure.
Note! Cables are not included in the weight of the complete system as this
depends on the specific cable length, but weight per unit length is
indicated.
4. References
N/A.
4. TECHNICAL DESCRIPTION
1. Purpose
This document describes the Fluenta Flare Gas meter, FGM 160. The main
components in the system are described and the measuring techniques are explained.
2. Abbreviations/Definitions
2.1 Abbreviations:
FGM Flare Gas Meter
TFS Transducer Full Size
2.2 Definitions:
N/A
3. General
3.1 Reference Conditions
The following reference conditions are used as a basis:
Measurement SI U.S.
Length : mm in
2
Area : m ft2
Volume : m3 or Sm3 MMCF or MMSCF
Mass : kg lb
3 3
Volume flow rate : m /h or Sm /h MMCFD or MMSCFD
Mass flow rate : kg/h lb/h
3
Density : kg/m lb/ft3
Pressure (absolute) : bar a psi
Temperature : °C F
3.3 Language
The FGM 160 is supplied with English text as standard.
· Large velocity variations for the gas flowing in the flare pipe.
The FGM 160 is designed to operate under these difficult conditions and the capability
to do so is verified by instruments presently in operation. The ultrasonic sensors are
wetted but non-intrusive, and will thus not disturb the flowing gas. The meter has no
mechanical moving parts, which makes the instrument less exposed to wear.
The problem associated with high flow velocities is, among others, that the gas
flowing in the pipe represents a source of noise, which reduces the recognisability of
the transmitted, ultrasonic signal. Also, high gas velocities will carry the ultrasonic
pulses along the pipe, which makes it even more difficult for the sensors to
communicate.
Low pressures, large pipe diameters and limitations on the amount of electric power
that can be applied due to explosive area regulations, are all elements that increase
the difficulty in obtaining good measurements. These problems are solved by using
two different types of signals, Continuous Wave and Chirp. This measurement
technique is described further in this document.
Figure 1 The FGM 160 system with one pair of ultrasonic sensors.
The FGM 160 measures the gas velocity by using the time of flight technique, which
means that the ultrasonic transducers communicate with each other by transmitting
and receiving ultrasonic signals.
Downstream (B)
n t21
L t12
D
q
Upstream (A)
Both transducers transmit and receive ultrasonic pulses and the difference in transit
time between the downstream pulse (from A to B) and the upstream pulse (from B to
A) is measured. When gas is flowing in the pipe, a pulse travelling against the stream
(upstream) will use longer time to reach the opposite transducer than a pulse
travelling with the flow (downstream). This time difference is used to calculate the
velocity of the flowing medium by the following equation:
L t -t
n= × 21 12
2 cos q t12 × t 21
where:
n = axial velocity of flowing medium without compensation for Reynolds
Number variation
L = distance between transducer tips
q = angle of intertransducer centre line to axis of pipe
t12 = transit time (sec) from Transducer (A) to Transducer (B) (downstream)
t 21 = transit time (sec) from Transducer (B) to Transducer (A) (upstream)
This is general signal type used in ultrasonic instruments. When measuring flare gases
at high velocities, the medium in the pipe line will generate significant acoustic noise.
This acoustic noise may have equal or higher amplitude than the CW signal, which
makes detection difficult, if not impossible. This signal is therefore only suitable for
measurements at low gas flow velocities.
Chirp signals are used in combination with CW signals for measuring flare gases at low
velocities. At higher velocities the instrument only utilizes Chirp signals.
The combination of Chirp and CW at low velocities enhances the accuracy of the FGM
160 measurements for these velocities.
The PCB stack module can be divided into five main components or units. A Local
Display has been standard for the FGM 160 since 2007, completing the PCB stack with
a total of 6 boards.
An entire EEx-d solution will be available on request. The EEx-e housing is then
removed, and the terminal blocks and the FGM 160 Unit are integrated in a common
EEx-d housing.
This solution eliminates the demand for on-site Operator/Service Control since full
access and system control is available from any location.
This solution also makes it possible for Fluenta AS to remote the system, assist with
diagnostics and offer online software updates and support. Software updates for DSP,
P&T and I/O can be upgraded on-the-fly.
The pressure input signal is either in form of a 2-wire 4-20 mA signal or through HART
transmitter modem. The locally mounted transmitter is either powered by the 24 VDC
power supply in the FGM 160, or an external source.
The pressure transmitter and the temperature transmitter are connected to the FGM
160 through internal barriers in the FGM 160 Field Computer. The analogue inputs are
realized as floating 20 ohm resistors, through which the loop current flows. The
common mode voltage range is within -10 to +24 volts with respect to the FGM 160’s
ground level.
Two of these pulse output channels can be configured as frequency output channels
with a frequency range from 10Hz to 4 kHz. These outputs can be configured e.g. for
mass or volume flowrate.
The FGM 160 has one analogue output channel that can be configured as a HART
output interface. The HART output interface supports function code 0, 1 and 3. Refer
to Fluenta AS doc. no: 72.120.306 – FGM 160 HART Interface Specification, for a
detailed description of the HART interface.
Refer to Fluenta AS doc. no. 72.120.305 – FGM 160 Modbus Interface Specification for
a full description of the Modbus interface.
6. Ultrasonic Transducers
6.1 Transducer Full Size (TFS)
The ultrasonic transducers mounted onto the flare pipe are approved for operation in
Zone 0 with safety class EEx ia IIC T6. They are mounted in transducer holders that
are welded on to the flare pipe at carefully selected angles, positioned with specially
designed mounting jigs.
A piezo-electric crystal is mounted inside the titanium housing at the front of the
transducer. When the crystal is subjected to an alternating electrical signal, it vibrates
with the same frequency as the electrical signal. The crystal is attached to the front
membrane of the titanium housing and this membrane vibrates with the crystal. The
membrane movement generates the ultrasonic signals. When a transducer receives
ultrasonic signals, the membrane vibrates and the crystal transfers this movement
into an electrical signal.
installation ensures that the transducer position remains constant even after the
transducer have been taken out for servicing.
7. References
N/A
1. Purpose
This document lists the fundamental formulas and data used in the Fluenta Flare Gas
Meter, FGM 160, to calculate flow velocity and volumetric and mass flow rate.
2. Abbreviations/Definitions
2.1 Abbreviations:
FGM Flare Gas Meter
Additional abbreviations used in this chapter are for simplicity explained in same
section where used.
2.2 Definitions:
Definitions used in this chapter are for simplicity given in same section where used.
3. Flow Calculations
Formulas and data used in the FGM 160 calculations are given in the following
sections.
Flow calculations performed by the FGM 160 can be derived from Figure 6.
2 (B)
n t21
L t12
D
q
1 (A)
Figure 6 Sensor alignment and parameters of importance for the flow calculations.
where:
v × D × P × T0 × Z0
Re =
Kin.Visc.× P0 × T × Z
Equation 2 Reynolds number calculation.
where:
Re = Reynolds number
P = Measured pressure in Bar A
P0 = 1.01325 barA (reference conditions)
Kin.Visc. = Kinematic Viscosity (See value below)
T0 = 288.15 K = 15 °C (reference conditions)
T = Measured temperature in Kelvin
Z0 = Compressibility factor at reference conditions
Z = Compressibility factor at operating conditions
k = f (Re)
Equation 3 Flow profile correction factor based on Reynolds number.
where:
_
v = k ×v
Equation 4 Average axial gas flow velocity calculation.
where:
P T0 Z0
QV = A × v × × × × 3600
P0 T Z
Equation 5 Volumetric flow rate calculation, at reference conditions.
where:
Qm = QV × (1 M ) × rb
Equation 6 Mass flow rate calculation based on volumetric flow rate at referenced
conditions.
where:
P T0 Z 0
M = × ×
P0 T Z
Qm = A × v × r b × 3600
Equation 7 Mass flow rate calculation based on average axial gas flow velocity.
Input:
Velocity of Sound (VoS) Calculated based on ultrasonic transit time
measurements.
Pressure (P) Measured with the Pressure Transmitter.
Temperature (T) Measured with the Temperature Transmitter.
Output:
Gas Density
Molecular Weight
Mass Flow rate
For more accurate density calculations, Enhanced Density Model can be used. In this
mode it is possible to enter the gas composition into the FGM configuration. It can
also be done via DCS. Second option allows keeping a more up-to-date gas
composition data in the FGM’s memory.
While using EDM, it is automatically chosen from two available scenarios – flaring
mode or purging mode. The switch is made depending on flow velocity. The switching
point is set by an operator through O&SC or DCS modbus. Flaring mode is default for
calculating mass being flared (high flow velocity) and purging mode (low flow
velocity) and takes into consideration the amount of nitrogen used to purge the flare
stack. In purging mode, less mass is being totalized because the amount of nitrogen
is not being taken into account while it is present in the volume flow.
Input:
Velocity of Sound (VoS) Calculated based on ultrasonic transit time
measurements.
Pressure (P) Measured by Pressure Transmitter.
Temperature (T) Measured by Temperature Transmitter.
Normalized Gas Composition Inserted via operator console or through DCS
Output:
Gas Density
Molecular Weight
Mass Flow rate
Defined gas composition can be entered via Modbus into registers presented below:
Register no. Value
1140 Molar fraction of C1, Methane. [%]
1141 Molar fraction of C2, Ethane. [%]
1142 Molar fraction of C3, Propane. [%]
1143 Molar fraction of C4, Butane. [%]
1144 Molar fraction of C5, Pentane. [%]
1145 Molar fraction of C6 and higher order hydrocarbons, Hexane ->. [%]
1146 Molar fraction of N2, Nitrogen. [%]
1147 Molar fraction of Co2, Carbon Dioxide. [%]
To turn on selected density model service operator need to change 10107 registers
through O&SC. For other option while choosing EDM please refer table below.
Register no. Value Description
0 Old model(FGM130)
10107 1 Enhanced model
2 Enhanced model, default composition
Velocity limit for change from purging to flaring mode in
10108 m/s
new enhanced density model (default 2 m/s)
Velocity limit for change from flaring to purging mode in
10109 m/s
new enhanced density model (default 1 m/s)
Gas density model used at last calculation (current register
values)
Read- 0: General gas density model (old FGM 130 model)
1025
only 1: Improved gas density model, Flaring scenario
2: Improved gas density model, Purging scenario (N2
fraction is calculated in addition to density and mol.weight)
Nitrogen fraction [%]. Only valid in purging scenario,
Read- otherwise value is 0.
1026
only Error conditions (underflow/overflow) are indicated by
values: -0.001 and 100.001.
4. References
N/A
1. Purpose
The following sections describe the most commonly used cables in Fluenta Flare Gas
Meter, FGM 160 system.
2. Abbreviations/Definitions
2.1 Abbreviations:
FGM 160 Fluenta Flare Gas Meter, model FGM 160
TFS Transducer Full Size
2.2 Definitions:
N/A
1 2 3 4 5 6 7 8 9
11 21 3
Code
Letter
1. Conductor Tinned, annealed, stranded copper.
2. Insulation R EP-rubber
3. Twinning Color coded cores twisted together and wrapped
with polyester tape.
4. PETP-tape
5. Bedding F Flame retardant halogen-free thermoset
compound.
6. PETP-tape
7. Armor O Tinned copper wire braid.
8. PETP-tape
9. Outer sheath U Flame retardant halogen-free and mud resistant
thermoset compound.
Code
Letter
Conductor Tinned, annealed, stranded circular copper.
Insulation R EP-rubber
Twinning Color coded cores twisted together and wrapped
with polyester tape.
PET-tape
Inner covering F Flame retardant halogen-free thermoset
compound.
PET-tape
Armor O Tinned annealed copper wire braid.
PET-tape
Outer sheath U Flame retardant halogen-free and mud resistant
thermoset compound.
5. References
NA
1. Purpose
The purpose of this procedure is to describe Fluenta AS’s preparation for shipment
and transport to ensure that the equipment will be correctly treated from the time of
leaving Fluenta AS’s works, throughout any transport period, until it has reached its
final destination. Details on unpacking, inspection and storage procedures are also
given.
2. Abbreviations/Definitions
2.1 Abbreviations:
FGM Flare Gas Meter
TFS Transducer Full Size
2.2 Definitions:
N/A
3. General
All Fluenta Flare Gas Meter (FGM 160), produced and supplied by Fluenta, will be
preserved, packed, marked and shipped according to this procedure.
4. Preservation
All items will be free of dirt, oil, grease and other contaminants before preservation
and packing commences.
4.1 General
The following describes how Fluenta AS will preserve the equipment supplied to the
customers. The equipment will be preserved at all stages from leaving Fluenta AS’s
works, until it is finally placed in service.
5. Marking
All items will be marked with labels showing tag numbers and if necessary,
description.
The packing list (one for each package) will contain the following information:
- P.O. No:
- MMT No.
- Name of equipment/material.
- Item, tag or code no.
- Quantity and description of goods.
- Size and Gross weight.
- Indication complete or partial delivery.
- Point of delivery.
- Origin of goods.
- HS Number.
- Shipping marks.
The shipping documents will be located as follows:
7. Unpacking
Initial preservation has been carried out on the equipment before leaving Fluenta AS.
Due to the delicate nature of the equipment, great care should be undertaken when
handling both unopened and opened crates.
The receiver should check that all items have been received according packing lists.
All plastic film and other cover materials should be removed before the equipment is
taken into use. Make sure that all "Cortec" have been removed before start-up.
8. Inspection
The equipment shall be inspected for damage and cleanliness at receipt at
construction site. Any damage shall be reported without undue delay to the project
and the supplier. No repair work should be attempted without prior inspection and
approval from the supplier.
· To be stored indoor.
· The equipment is preserved for 12 months storage. The preservation status should
be inspected and if necessary preservation maintenance should be carried out. The
equipment should be inspected every 6 weeks.
Temperature: + 15 °C to + 30 °C
Relative Humidity: < 45 %
The items should be stored in their original packing until they arrive at the final
destination.
10. References
N/A
1. Purpose
The purpose of this procedure is to provide a traceable point-by-point installation
guideline for the Fluenta Flare Gas meter, Field Computer (FGM 160) system. This
document provides details on the different options that are available to the FGM 160
system, the installation of the base system, and the optional configurations. The
optional configurations include the two types of transducer, possible upgrade from
previous Fluenta Flare Gas Meters, and the different interfaces available from the Flow
Computer to the Plant Control System. The procedure also provides a means to
establish an “Installation and Hook-Up Record” to document the installation.
2. Abbreviations / Definitions
2.1 Abbreviations
2.2 Definitions
Metering Spool Section – A section of pipe that has the transducer, pressure, and
temperature holders already mounted.
Center flush – The center of the tip of the transducer is flush with the
inner wall of the pipe.
Edge-Flush – The part of the transducer tip that is inserted furthest into
the transducer holder/ball valve, is flush with the inner wall
of the pipe
Insertion depth – The distance from the tip of the transducer to the raised
part of the transducer flange.
3. General
The FGM 160 system supplied from Fluenta is designed to work with no major
preparation. Due to the complexity and the required accuracy of the measurements it
is mandatory to obtain a very high degree of precision and care during all phases of
the installation.
This procedure includes the required steps from unpacking to commissioning. After
unpacking and inspection of the received goods has been carried out, the system
should be ready for installation. The description of the installation of the system is
divided in subsections as follows:
Note that warranty for the transducers only applies if certified personnel install the transducers.
Certified personnel include Fluenta service engineers, service engineers of our agents who have
received proper training and operators who have attended and completed Fluenta’s 2-day
Operators Training Course.
4. Unpacking
4.1 Inspection of Goods
Installation of the equipment supplied by Fluenta must never occur without the
inspection of the supplied goods carried out first. This should be performed according
to the instructions and tasks described in:
The important issue is to verify the goods with the packing list and inspect for
damages caused by transportation. Save packing material for storing and reshipping
of the equipment, if required.
For more detailed equipment information and equipment ratings, please refer to: FGM
160 – Hazardous Area Installation Guidelines[1].
5. Transducer/Probe Installation
5.1 Installation of Transducer Holders
There are three alternatives for mounting the transducer holders. The first is using a
metering spool piece that have the transducer, pressure, and temperature holders
already installed at a mechanical workshop. The second is what is referred to as
“Cold Tapping”, where the holders are installed on a section of pipe that is shut off
from the flare system. The third option is what is referred to as “Hot Tapping”, where
the holders are mounted onto a flare pipe that is active. The metering spool piece is
assembled in a mechanical workshop, and “Cold Tapping” and “Hot Tapping” are done
by welders under the supervision of Fluenta personnel.
Pipe Size
6” – 10” 12” – 72”
Perpendicular Distance
Operational upstream perpendicular distance 525 mm 500 mm
Operational downstream perpendicular distance 475 mm 500 mm
Retracted upstream perpendicular distance 770 mm 730 mm
Retracted downstream perpendicular distance 690 mm 730 mm
Length
Operational 700 mm 700 mm
Retracted 1,030 mm 1,030 mm
5.2.1 Orientation
Figure 10: Vertical flare boom with the transducer holders and transducers installed.
The orientation of the transducers is irrelevant for installation on a vertical
pipe run.
Fluenta recommends using the special Figure 14: Marking jig used for positioning
marking jig, ref. Figure 14. of the transducer holders.
Adjust the marking-jig to fit the pipe-
diameter. Clamp it to the pipe and mark the centre-position for both transducer
holders. If no marking jig is available, other means of finding and marking the spots
must be used. We will describe two methods, but there are numerous ways this can
be done.
Spot B
Spot A D
πD
Figure 17: Fold the paper in two. Mark the fold. This will give you spot B.
Remove the marking-jig and clamp the welding-jig to the pipe and mount the
transducer holder. Mark the hole for the sensors on the pipe wall following the inside
rim of the transducer holder when they are mounted in the welding-jig. Repeat for
the other transducer holder. The holes can now be cut following the marked line on
the pipe-wall. Sharp edges and burrs must be avoided. A hole with smooth edges is
required. Do not make the hole to small, follow the inside rim.
After the holes are made, ensure that the inner edges are grinded to be smooth, and
beveled the correct way. Ref. Figure 18. Before the welding starts, the groove angle
must be grinded on the holders. Normally the holders must be taken off the welding-
jigs for grinding/adjustment to get the right opening and joint, ref. Figure 19.
When correct alignment of both transducer holders are ensured (see section
5.25.2.3), the welder can weld and fill out both transducer holders. Be aware that as
the welding progresses, the transducer holders can be pulled off their angles by the
welding process. Therefore it is necessary to pay close attention during the welding,
regularly checking the angles with the digital electronic level.
Figure 21: Welding jig and transducer Figure 22: Transducer holder welded to
holder. the pipe.
This job needs a skilled welder as precision and accuracy is demanded to get the
transducer holders welded into their right positions. The transducer holders are
welded onto the pipe according to the buyers welding procedure. Next step will be
NDT and final approval of the welding. The welding-jigs can be dismounted when the
transducer holders are properly connected to the pipe as shown in Figure 22.
Figure 23: The sighting Figure 24: The sighting tool Figure 25: The stop washer
tool for the 42°/48° for the sighting tool for the
for 45° transducer holders.
transducer holders 42°/48° transducer
. holders.
The second type of sighting tool is made for transducer holders that are mounted on
pipes with a diameter of 10” and less and with 42°/48° transducer holders, ref. Figure
23. This set of tools use the path of light for verification like the first. As the
transducer holder’s mounting angles are not equal, these tools require some
adjustments before they can be used. The set comes with a pair of stop washers,
shown in Figure 25. The tool must penetrate the transducer holder to the same
depth as the transducer.
Figure 24: The sighting tool for the 45°/45° transducer holders
Stop washer
Sighting Tool
When using the sighting tool for pipes that have a diameter greater than 10”, insert
the sighting tool into the transducer holder so that the flange of the sighting tool is
flush with the flange of the transducer holder. This is shown in Figure 26.
When using the sighting tool for pipes that are 10” and less, use the measurement
from the special tool in described in section 5.3.1 to find the correct depth for the
transducer. This depth should be the same for the sighting tool. Measure from the
narrow end of the sighting tool and tighten the stop washer at that position. Insert
the sighting tool so that the stop washer is flush with the flange on the transducer
holder, this is shown in Figure 27. There is a groove in the head of this type of
sighting tool shown in Figure 28. Align one sighting tool with the pipe, and rotate the
other until the light is visible. Adjust the sensor holder so that the circle of light is
Rotate
Figure 28: Look through the holes on the sighting tool. Rotate the sighting tool on
the left to get a correct alignment.
seen as described below.
When the transducer holders are properly aligned and the sighting tools are inserted,
it is possible to see a perfect circle of light when looking through the hole in one of the
sighting tools, shown in Figure 29. If there is not enough ambient light, it may be
necessary to shine a light source through the hole in the opposite sighting tool.
Figure 33: The insertion depth (green arrow) must be reduced (red arrow)
according to the angle of the transducer holder
As a result of the reduced insertion depth, the distance between the transducer tips
will increase (see Figure 34). The transducer tip distance is a parameter that directly
affects the flow velocity calculations, therefore the transducer distance must be
updated in the configuration of the flow computer.
For the FGM 160 the transducer distance can be found in the O&S Console software
under Config – Config Main Page – Mechanical Parameters – Measured (length in m).
For a FGM 130 the transducer distance is either set by command 278 or in the
software:
Figure 34: When the transducers are retracted, the transducer distance will increase
from the original distance (red arrow) to the new transducer distance (green arrow).
This must be updated in the flow computer.
For an installation where the transducer-holder angles are 48° and 42°, the retraction
needed for each transducer is 16.2mm for the 48° transducer (see Figure 36), and
20mm for the 42° transducer (see Figure 37). The transducer distance must then be
increased with 36.2mm (16.2mm+20mm) in the flow computer configuration.
Verify that the installed ball valves are gas tight (no gas leaks). This should be done
by the on-site personnel - using a gas monitoring device. Measure and adjust the
installation depth of each transducer, which is set by fastening the A-lock lock-ring.
Mount the transducer/packbox. Open the ball valve, and push the transducer all the
way in, until meeting the A-lock locker ring. Fasten the A-lock nut to the transducer
packbox.
3 4 Screw in the
Insert the transducer locking nut
a) b)
c) d)
Figure 39: The FGM 160 Field Computer mounting bracket versions.
Power source should not be connected until verification of supply voltage has been
performed. Main fuses should not be inserted at any stage of the installation phase
All cables should be connected to the terminals in the Ex-e enclosure of the FGM 160.
The blue terminals are IS (Intrinsically Safe) and are connected to the field computer
through internal IS barriers. The gray terminals are not connected to an IS barrier,
and are meant for signals between the field computer and safe area equipment and
systems.
The ultrasonic transducer cables are already prepared from the Fluenta production.
These cables should be handled with care.
Verify the labeling/tag name on the cable.
Pull the cable through its respective gland;
make sure that the cable gland is of the
required type and size. Secure the cable
and cable gland.
Upstream Ultrasonic
It is recommended that the cable between
Transducer
the FGM and the transducers is kept as
short as possible, 3 meters is supplied as a
standard. If this is not possible to Downstream Ultrasonic
accomplish, the cable length should not Transducer
exceed 10 meters. For other lengths than
standard, Fluenta must be notified.
The ultrasonic transducers shall be connected as follows. This is done at the Fluenta
production facilities.
Upstream:
Ch1Up–IS
Ch1Up+IS
Ch1Up_G
Downstream:
Ch1Dn-IS
Ch1Dn+Is
Ch1Dn_G
The FGM 160 can interface either to 4-20 mA current loop transmitters or HART
transmitters. Depending on the transmitter interface to the FGM 160, a connection
described in figures below should be used. Up to four HART transmitters can be
connected to the HART input terminals, e.g. if condition based maintenance scheme is
utilized with double or dual transmitters.
The pressure and temperature inputs at the FGM 160 are always configured as active
current loop inputs (i.e. the pressure and temperature transmitters are always
powered form the FGM 160 field computer).
T P
4-20mA / HART
4-20mA / HART
Control Room
4-20mA (HART)
Pulse/frequency/
level
DCS port, Modbus
Operator
Console Service port
The Service port is for the Operator & Service Console. This connection must be
available in the safe area in order to enable Fluenta’s support personnel to check the
meter’s performance, configure the meter and upload new firmware. Figure 47 shows
the different connections. Operator Console and DCS wiring is normally not a part of
Fluenta’s scope of work.
For detailed information regarding the DCS port wiring, please refer to:
Please refer to: FGM 160 – Operator Console Description [5], for more detailed
information.
Each of the current loop outputs can be configured either as active or passive output.
In active output configuration, the current loop is powered from the FGM 160 field
computer. In passive output configuration, an external power source is required.
In default configuration, all current loop outputs are configured as active outputs.
72.120.606/D Page 80 of 211
Installation & Hook-Up Instructions
- Analog output.
The output is assigned to a specific parameter/process variable and
configured with a desired range.
Current Loop Outputs are replaced by Foundation Fieldbus Outputs in FGM 160
Foundation Fieldbus configuration.
2300.0
2100.0
1900.0
1700.0
Load resistor [Ω]
1500.0
700.0
500.0
300.0
100.0
0 5 10 15 20 25 30 35 40 45 50
Loop voltage [V]
+30V +30V
Load
resistor
CLx-in
CLx-in
Low side load
CLx-out
Load
ONLY for single resistor
output configuration
0V 0V
Figure 53: Current loop active output, High side load and Low side load
+ +
CLx-in
Load
resistor
External power
External power
Figure 54 Current loop passive output, High side load and Low side load
30V 30V
CLx-in CLx-in
CLx-out CLx-out
CLx-in CLx-in
CLx-out CLx-out
0V
0V
+ +
External power
External power
CLx-in CLx-in
CLx-out - CLx-out -
CLx-in CLx-in
CLx-out CLx-out
FGM 130
Control Room
Sensor Cables
Power Cables
Data Cables
Operator
Console
Safe
Area
The table below shows the components of the FGM 130 that can be re-used when
upgrading to the FGM 160.
7. References
[1] FGM 160 Preservation, Packing, Unpacking and Storage Procedure
[2] FGM 160 – Hazardous Area Installation Guidelines
[3] FGM 160 - Field Wiring Diagram, Fluenta Doc.no.: 77.120.509
[4] FGM 160 – DCS Modbus Interface Specifications
[5] FGM 160 – Operator Console Description
[6] FGM 160 – HART Output Interface Specification
1. Purpose ...................................................................................................... 94
2. Abbreviation/Definitions ................................................................................ 94
2.1 Abbreviations........................................................................................................................... 94
2.2 Definitions................................................................................................................................ 94
3. General ....................................................................................................... 94
4. Unpacking ................................................................................................... 94
4.1 Inspection of Goods ................................................................................................................. 94
5. Ex-Certificaton and Marking ........................................................................... 94
5.1 Ex-Classification Marking ......................................................................................................... 94
5.2 FGM Sensor Marking ............................................................................................................... 95
5.3 Equipment Information ........................................................................................................... 95
5.4 Pressure and Temperature Transmitter Interface Specifications ........................................... 96
5.5 Manufacturer Information ...................................................................................................... 97
6. References .................................................................................................. 97
7. APPENDIX 1 ................................................................................................ 97
1. Purpose
This document provides installation guidelines for the FGM 160 Flare Gas Meter in
order to ensure safe use of the system in a potential explosive atmosphere.
2. Abbreviation/Definitions
2.1 Abbreviations
FGM 160 Fluenta Flare Gas meter, Model FGM 160
TFS Transducer Full Size
2.2 Definitions
Ex-d/e - Equipment in Ex-d explosion proof enclosure and connection
housing in Ex-e enclosure.
3. General
This document is not a complete installation and hook-up instruction for the FGM 160.
For complete installation instructions, please refer to Installation and Hook-Up
Instructions.
4. Unpacking
4.1 Inspection of Goods
Installation of the equipment supplied by Fluenta must never occur without the
inspection of the supplied goods carried out first. This should be performed according
to relevant quality assessment schedules.
Figure 60: ATEX certification marking of the Fluenta Flare Gas Meter, FGM 160.
*)
Electrical rating (input power) +24 VDC nom. (20 – 32 VDC)
*)
: The FGM 160 requires +24 VDC input. If +24 VDC is not available, an optional
110-230 VAC/24 VDC converter can be supplied by Fluenta, mounted in an Ex-
d explosion proof enclosure.
Note!
The FGM 160 Field Computer is not equipped with an ON/OFF switch. Thus, it should
be assumed that power is present unless it is made absolutely sure that no power is
present at the terminals.
Io = 0.09A Uo = 27.3V
Ro= 304 ohm Po= 0.62W
Co=0.088yF Lo = 3.5mH
Lo/Ro=58uH/ohm
Figure 62 Specifications for 4-20 mA/HART inputs from Pressure and Temperature
transmitter connections.
6. References
FGM 160 Installation & Hook-Up Instructions.
7. APPENDIX 1
Connection of Ex Pressure and Temperature transmitters is outlined in Figure 63.
Requirements for transmitters that do and do not comply with IEC 60079-11 Ed. 5,
Clause 6.3.12 is listed below, as well as requirements for transmitters with Ex-d
protection.
Intrinsic safe parameters for each Intrinsic safe parameters for each
transmitter: transmitter:
No special requirements
6. OPERATING INSTRUCTIONS
1. Purpose
This document describes the Fluenta Flare Gas Meter, FGM 160 hardware and
software, and the device integrity.
2. Abbreviations/Definitions
2.1 Abbreviations:
TFS Transducer Full Size
DCS Distributed Control System
O&S C Operator & Service Console
2.2 Definitions:
Operator & Service Console - PC software with graphical interface for configuring
and monitoring the FGM 160 Field Computer
3. General Information
3.1 Hardware Description
The FGM 160 Field Computer, illustrated in Figure 64, is designed as a distributed
system. The FGM 160 consists of five or six modules, the Digital Signal Processing
(DSP) module, the Analogue Front End (AFE) module, the Pressure & Temperature
(P&T) module, Input/Output (I/O) module, Intrinsic Safe Barrier (IS Barrier) module,
Surge Protection module and the Local Display. A distributed system gives several
advantages. This design will be more flexible with respect to future expansions and
modifications, as the total processing load for the system can be divided on several
modules. Thus, the danger of overloading a single CPU unit is reduced.
For detailed information regarding Hazardous Area installation and operation, please
refer to Chapter 5. – Section 5.3 Hazardous Area Installation Guidelines and Fluenta
Doc. no. 75.120.200 (FGM 160 Hazardous Area Certificates).
Control Room
Sensor Cables
Power Cables
Safe
Area
Figure 65 – FGM 160 Hook-Up, with the Field Computer, Ultrasonic Transducers, Pressure and
Temperature Transmitters, and connections to Safe Area equipment.
For detailed equipment information and equipment ratings, please refer to Chapter 5
– Section 5.3 Hazardous Area Installation Guidelines.
One is dedicated for communication with a DCS system. The second is a service port
for configuration and monitoring of the FGM 160 system.
DCS Output is disabled in FGM 160 Foundation Fieldbus configuration.
The FGM 160 can also be configured to provide a pulse or frequency output signal.
The pulse output will represent a totalised increment (of e.g. volume or mass),
whereas the frequency output will represent a process parameter (e.g. volume flow
rate, mass flow rate etc.)
It should be noted, the O&S C is required to replace the default settings with actual
applicable settings provided by customer. Fluenta service engineers and partners will
always setup the FGM 160 according latest submitted parameters from the Client
when installing and commissioning the FGM 160. Fluenta’s service engineers and
partners carry always with them the O&S C.
4. Operating Procedure
4.1 Introduction
This section provides information about how to operate the FGM 160 field computer.
The FGM 160 is a field mounted stand-alone ultrasonic gas flow measurement system,
and does not require any safe area communication device in order to operate.
However, in order to continuously monitoring data and the meter performance, it is
recommended to use the Operator & Service Console (O&S C). This program will
provide hands-on process and status data continuously, with possible remote access
to the FGM 160 system from any remote system with the appropriate remote control
software installed.
1. Connect all power, input and output signals and communication cables according to
the project specification and all relevant procedures and instructions.
2. Make sure that the power cable is connected to a suitable power source, either
directly to a 24 VDC supply or through a 110-240 VAC / 24 VDC converter.
3. Turn on the power to the FGM 160. There is no power switch on the FGM 160 Field
Computer, so the power must be turned ON and OFF by an external switch or
similar, preferably in safe area.
4. On startup, the FGM 160 will go through a boot and an initialization sequence
before entering the standard operational (measurement) mode.
5. When the FGM 160 has entered the standard operational (measurement) mode,
the meter will, according to the system configuration, carry out transit time
measurements, retrieve pressure and temperature data, calculate volumetric and
mass flow rates and either actively output a set of predefined parameters at the
analog 4-20mA outputs, or make a set of process parameters available for DCS
HART or Modbus communication.
Figure 66 Download of system configuration using the Operator & Service Console.
The system configuration parameter file can be downloaded from the FGM 160 using
the Operator & Service Console, ref. Figure 66, by entering the “Config Main Page”
through the “View – Config” menu bar. The system configuration can either be copied
to the clipboard and pasted into a document, or saved directly to a file.
Some of the system configuration parameters are also available through the DCS
Modbus registers. However, parameters that should only be accessed by authorized
personnel are not accessible through this communication line. For a full listing of
accessible configuration parameters through the DCS Modbus interface, refer to
Chapter 6 – Section 6.2 DCS Modbus Interface Specifications.
· Power
This LED will have a green light when the system power is ON.
· Status
This LED will light:
GREEN; if no Alarms are active (system status OK).
· Comm
This LED will light:
GREEN; during Modbus frame reception or sending.
· Meas
This LED will blink GREEN at a regular cycle, indicating that ultrasonic
measurement cycle sequence is active.
Fluenta AS
Sandbrekkeveien 85
P.O. Box 115, Midtun
N-5828 Bergen
NORWAY
Phone:+47 55 29 38 85
E-mail: support@Fluenta.com
Error check can be carried out by using the Operator & Service Console
NOTE!
Before any work can be carried out with the FGM 160 field computer, a hot
work permit must be obtained.
Do not connect or disconnect any signal wires unless the power is turned
OFF!
Do not open the Ex-d enclosure containing the field electronics in hazardous
area, without first making sure that the conditions approve such action.
Preferably, and as a general rule; the Ex-d enclosure should only be opened
indoors in e.g. a workshop in safe area.
· Power
Indication: The LED is not ON (no green light).
Status: System Power is OFF, or LED does not work.
Action: Check that the system Power wires are connected and that 24 VDC
is present at the power input terminals.
· Meas
Indication: The LED is steady OFF or steady GREEN.
Status: The FGM 160 is not in standard operational (measurement) mode.
Action: Check the Alarm log for any error messages indicating any cause for the
problem. Turn the system Power OFF and ON again. If the situation remains
unchanged, contact Fluenta AS for guidance.
Figure 67 By activating the “Log Measurement Data” function at the “Log Data” window,
any or most parameters can be logged to a data file. The data log file name will
be generated automatically based on the current date and time.
By using the Operator & Service Console, it is also possible to carry out remote
diagnostics. Thus, a Fluenta AS service engineer, being granted access to a specific
system by the end operator, can monitor the performance of the meter and carry out
analysis based on logged and live data. This function requires internet connection, and
communication wires to service port.
5. References
[1] FGM 160 – Hazardous Area Installation Guidelines
***************************************
********** System Parameters **********
***************************************
Field Computer Type: FGM 160
Serial number: 2006-0102
Tag number: 1-TAG-1
Company: FLUENTA AS
Instalation:
Description:
Local Display:
SW Version DSP:
EXAMPLE
System Configuration:
Sandbrekkeveien 85
10" LP Flare
*******************************************
********** Communication Parameters **********
*******************************************
---------------------------------------------------------------
**********************************************
************ System Configuration ************
**********************************************
EXAMPLE
Pipe diameter: 0.3800 m
Transducer distance (M): 0.5370 m
Transducer angle: 45.0 deg
**********************************************
*********** Input Signal Parameters ***********
**********************************************
Pressure input Current Loop (4-20mA)
Temperature input Current Loop (4-20mA)
Current loop ranges
Temperature, 4mA value: 255.15 [Kelvin]
Temperature, 20mA value: 533.15 [Kelvin]
Pressure, 4mA value: 1.013 [BarA]
Pressure, 20mA value: 12.044 [BarA]
Alarm limits
Temperature, Hi limit: 533.15 [Kelvin]
Temperature, Lo limit: 255.15 [Kelvin]
Pressure, Hi limit: 12.044 [BarA]
Pressure, Lo limit: 1.013 [BarA]
**********************************************
********** Output signal parameters **********
**********************************************
EXAMPLE
Current loop 1, 4mA value: 0.00
Current loop 1, 20mA value: 2124000.00
Current loop 2, 4mA value: 0.00
Current loop 2, 20mA value: 50.00
Current loop 3, 4mA value: 4.00
Current loop 3, 20mA value: 20.00
Current loop 4, 4mA value: 4.00
Current loop 4, 20mA value: 20.00
Current loop 5, 4mA value: 4.00
Current loop 5, 20mA value: 20.00
Current loop 6, 4mA value: 4.00
Current loop 6, 20mA value: 20.00
**********************************************
Z Standard:
Z Operational:
EXAMPLE
Ref Temperature (std. conditions):
Ref Pressure (std. conditions):
1.000
1.000
15.00 ºC
1.01325 BarA
**********************************************
******** Sensor Calibration Parameters *******
**********************************************
1. Purpose .....................................................................................................126
2. Abbreviations/Definitions .............................................................................126
2.1 Abbreviations:........................................................................................................................ 126
2.2 Definitions: ............................................................................................................................ 126
3. General Information ....................................................................................126
3.1 Process Parameter Units ....................................................................................................... 127
4. Registers ....................................................................................................127
4.1 Modbus Register Base Addresses.......................................................................................... 127
4.2 Modbus Register Addresses in FGM 160 ............................................................................... 128
4.3 FGM 160 Modbus register map for DCS port ........................................................................ 130
4.3.1 System ID Number ......................................................................................................... 130
4.3.2 Data Time Tag and Primary Measurements Registers .................................................. 130
4.3.3 Secondary Measurements Registers ............................................................................. 131
4.3.4 Totalized Values Registers ............................................................................................. 132
4.3.5 24-Hour Totalized Values Registers ............................................................................... 132
4.3.6 Parameter Unit Registers............................................................................................... 134
4.3.7 Internal System Parameter Registers ............................................................................ 135
4.3.8 Gas Composition Parameter Registers .......................................................................... 135
4.3.9 Real Time Clock Registers .............................................................................................. 136
4.4 Data Encoding of FGM 160 Register Values .......................................................................... 136
4.4.1 Byte Ordering for FGM 160 Register Values.................................................................. 137
4.4.2 Bit Ordering of Each Character or Byte ......................................................................... 138
4.4.3 The “Byte Count” Field .................................................................................................. 138
4.4.4 Register Address Spacing ............................................................................................... 138
5. Number Representation ...............................................................................139
5.1 Single Precision Floating-Point Format.................................................................................. 139
6. Examples ...................................................................................................140
6.1 Function Code 3, Read registers ............................................................................................ 140
6.2 Function Code 16, Write to registers..................................................................................... 140
6.3 Function Code 8; Diagnostics................................................................................................ 141
6.3.1 Sub-function 0 (Return Query Data) ............................................................................. 141
7. Exception responses ....................................................................................141
7.1 Standard Modbus Exception Codes....................................................................................... 141
7.2 Fluenta Defined Exception Code ........................................................................................... 142
8. Physical Layer .............................................................................................142
8.1 RS422 Compatible Master Node (DCS).................................................................................. 142
8.2 Two-Wire Configuration (default configuration)................................................................... 143
8.3 Four-Wire Configuration........................................................................................................ 144
8.4 Cable Specifications ............................................................................................................... 145
8.5 Visual diagnostic .................................................................................................................... 146
8.6 RS485 Modbus Connections at FGM 160 .............................................................................. 146
9. References .................................................................................................148
1. Purpose
This document describes the Modbus RTU Protocol and the Modbus ASCII Protocol,
which are implemented in the Fluenta Flare Gas Meter, FGM 160 system. Function
codes for operating the system are specified, the various registers are described and
examples of Modbus communication are given.
2. Abbreviations/Definitions
2.1 Abbreviations:
FGM 160 Flare Gas Meter, Model FGM 160
ASCII American Standard Code for Information Interchange
RTU Remote Terminal Unit
2.2 Definitions:
Modbus A high-level protocol for industrial networks developed by Modicon. It
defines a request/response message structure for a client/server
environment.
3. General Information
Parameters in the FGM 160 are accessible from a serial interface by using the Modbus
protocol. All or just a selected range of parameters in an array can be accessed in a
single read or write operation, 62 in RTU mode and 30 in ASCII mode (due to memory
restrictions in the FGM 160). Some registers contain ‘Read only’ parameters, while
others contain ‘Read / Write’ parameters. All registers in the FGM 160 are 32-bit wide.
Register values are represented as 32-bit floating point values in IEEE 754 format.
The FGM 160 can be configured for Modbus RTU mode or Modbus ASCII mode. In
Modbus RTU mode, each 8-bit byte in a message, contains two 4-bit hexadecimal
characters. In Modbus ASCII mode, each 8-bit byte in a message, is sent as two
ASCII characters.
Function
Description
Code
Read multiple registers, 32-bit floating point format, single precision
3
(IEEE 754).
Write multiple registers, 32-bit floating point format, single precision
16
(IEEE 754).
Loopback test. Only sub-function code 0 is implemented (Return
8
Query Data).
NOTE: Registers accessed by Function Code 3 and 16 are 32-bit floating point
registers, NOT 16-bit integer registers as defined in the Modbus standard.
The Modbus slave address of the FGM 160 is configurable in the range 1-247 (1 – F7
Hex):
Default Modbus slave address for system 1 and 2 is: 224 (E0 Hex).
4. Registers
4.1 Modbus Register Base Addresses
The FGM 160 Modbus register base addresses are shown below. These are individually
configurable in the range 0 - 65333. However, the offset between succeeding register
base addresses should at least be 200 if system 1 and system 2 is configured with the
same Modbus slave address.
The Modbus Register Base Addresses can be read from registers at the fixed register
addresses 65534 and 65535:
However, “Holding register address” is not the same as the register address in the
data address field of the Modbus message.
Examples:
- Holding register 40001 is addressed as register 0000 in the address field of the
Modbus message. (The function code field already specifies a “holding register”
operation. Therefore the “4XXXX” reference is implicit.)
The register map below refer to the register addresses in the data address field of the
Modbus message (not the “Holding register addresses”).
Also note that the register addresses given in the register map below are OFFSET
addresses relative to the “Modbus Register Base Addresses”.
Examples:
- Modbus Register Base Address for system 1 = 1000 and “Register spacing = 1”
(default configuration):
The “Volume Flow rate at Standard Conditions” register for system 1, can be
found at address 1008 (1000 + 8). This is the register address in the data
address field of the Modbus message, corresponding “Holding register address”
will be 41009.
- Modbus Register Base Address for system 2 = 2000 and “Register spacing = 1”
(default configuration):
The “Volume Flow rate at Standard Conditions” register for system 2, can be
found at address 2008 (2000 + 8). Corresponding “Holding register address”
will be 42009.
- Modbus Register Base Address for system 1 = 1000 and “Register spacing = 2”:
The “Volume Flow rate at Standard Conditions” register for system 1, can be
found at address 1016 (1000 + 16). This is the register address in the data
address field of the Modbus message, corresponding “Holding register address”
will be 41017.
Register addresses in register map below are OFFSET addresses relative to the
“Modbus Register Base Addresses”.
Address Def.
Parameter R/W Min Max
RS=1 RS=2 Unit
0 0 ID High word (Production Year) R -- 2002 2099
1 2 ID Low word (Serial number) R -- 0 --
Address Def.
Parameter R/W Min Max
RS=1 RS=2 Unit
2 4 Data Time Tag - Year R 2002 2091
3 6 Data Time Tag - Month R 1 12
4 8 Data Time Tag - Day R 1 31
5 10 Data Time Tag - Hour R 0 24
6 12 Data Time Tag - Minute R 0 59
7 14 Data Time Tag - Second R 0 59
Volume Flow rate at Standard
8 16 R Sm3/h -- --
Conditions
Volume Flow rate at Actual
9 18 R m3/h -- --
Conditions
10 20 Mass Flow rate R kg/h -- --
11 22 Gas Flow Velocity R m/s -- --
12 24 Gas Flow Velocity w/Threshold R m/s -- --
Gas Flow Velocity,
13 26 R m/s -- --
uncompensated
Address Def.
Parameter R/W Min Max
RS=1 RS=2 Unit
20 40 Velocity of Sound R m/s -- --
21 42 Gas Density R kg/m3 -- --
22 44 Molecular Weight R g -- --
23 46 Alarm Status *) R 0
Gas Density at Standard
24 48 R kg/Sm3 -- --
Conditions
25 50 Gas density model used R ---- 0 2
26 52 N2 (nitrogen) fraction R % 0 100
30 60 Pressure **) R/W bar A
31 62 Temperature **) R/W °C
32 64 Pressure, HART Transmitter 1 R bar A
33 66 Pressure, HART Transmitter 2 R bar A
34 68 Temperature, HART Transmitter 1 R °C
35 70 Temperature, HART Transmitter 2 R °C
36 72 HART Transmitter Status ***) R 0 6666
*)
: Alarm Status word (bit coded 16-bit word):
To interpret the Alarm status bits, the integer part of the register value should first be
converted to binary format.
**)
: Pressure and Temperature:
The Pressure and Temperature registers are normally Read Only registers, but the
FGM 160 can be configured to accept pressure and temperature data input from DCS
through these registers.
***)
: HART transmitter status word (4 digit coded, ABCD):
Code Description
0 Transmitter not found at initialisation.
1 Status OK.
2 Timeout, transmitter not responding.
3 Wrong code in transmitter response.
4 Checksum error in transmitter response.
5 Wrong data format in transmitter response.
6 Illegal number, NaN (Not A Number).
Example:
Address Def.
Parameter R/W Min Max
RS=1 RS=2 Unit
Totalized Volume at Standard
40 80 R Sm3 0 1000000
Conditions
Totalized Volume at Actual
41 82 R m3 0 1000000
Conditions
42 84 Totalized Mass R kg 0 1000000
Totalized Vol. at Std. Cond.
43 86 R 1000000 0 1000000
Overflow Count
Totalized Vol. at Act. Cond.
44 88 R 1000000 0 1000000
Overflow Count
45 90 Totalized Mass Overflow Count R 1000000 0 1000000
Address Def.
Parameter R/W Min Max
RS=1 RS=2 Unit
Last 24 Hour Totalized Volume at
50 100 R Sm3 0 --
Std. Cond.
Last 24 Hour Totalized Volume at
51 102 R m3 0 --
Act. Cond.
52 104 Last 24 Hour Totalized Mass R kg 0 --
Start Time for Last 24 Hour
53 106 R HH,MMSS 0,0000 23,5959
Totalisation
Address Def.
Parameter R/W Min Max
RS=1 RS=2 Unit
(Last-1) 24 Hour Totalized Volume at
54 108 R Sm3 0 --
Std. Cond.
(Last-1) 24 Hour Totalized Volume at
55 110 R m3 0 --
Act. Cond.
56 112 (Last-1) 24 Hour Totalized Mass R kg 0 --
Start Time for (Last-1) 24 Hour
57 114 R HH,MMSS 0,0000 23,5959
Totalisation
(Last-2) 24 Hour Totalized Volume at
58 116 R Sm3 0 --
Std. Cond.
(Last-2) 24 Hour Totalized Volume at
59 118 R m3 0 --
Act. Cond.
60 120 (Last-2) 24 Hour Totalized Mass R kg 0 --
Start Time for (Last-2) 24 Hour
61 122 R HH,MMSS 0,0000 23,5959
Totalisation
(Last-3) 24 Hour Totalized Volume at
62 124 R Sm3 0 --
Std. Cond.
(Last-3) 24 Hour Totalized Volume at
63 126 R m3 0 --
Act. Cond.
64 128 (Last-3) 24 Hour Totalized Mass R kg 0 --
Start Time for (Last-3) 24 Hour
65 130 R HH,MMSS 0,0000 23,5959
Totalisation
(Last-4) 24 Hour Totalized Volume at
66 132 R Sm3 0 --
Std. Cond.
(Last-4) 24 Hour Totalized Volume at
67 134 R m3 0 --
Act. Cond.
68 136 (Last-4) 24 Hour Totalized Mass R kg 0 --
Start Time for (Last-4) 24 Hour
69 138 R HH,MMSS 0,0000 23,5959
Totalisation
(Last-5) 24 Hour Totalized Volume at
70 140 R Sm3 0 --
Std. Cond.
(Last-5) 24 Hour Totalized Volume at
71 142 R m3 0 --
Act. Cond.
72 144 (Last-5) 24 Hour Totalized Mass R kg 0 --
Start Time for (Last-5) 24 Hour
73 146 R HH,MMSS 0,0000 23,5959
Totalisation
(Last-6) 24 Hour Totalized Volume at
74 148 R Sm3 0 --
Std. Cond.
(Last-6) 24 Hour Totalized Volume at
75 150 R m3 0 --
Act. Cond.
76 152 (Last-6) 24 Hour Totalized Mass R kg 0 --
Start Time for (Last-6) 24 Hour
77 154 R HH,MMSS 0,0000 23,5959
Totalisation
(Last-7) 24 Hour Totalized Volume at
78 156 R Sm3 0 --
Std. Cond.
(Last-7) 24 Hour Totalized Volume at
79 158 R m3 0 --
Act. Cond.
80 160 (Last-7) 24 Hour Totalized Mass R kg 0 --
Start Time for (Last-7) 24 Hour
81 162 R HH,MMSS 0,0000 23,5959
Totalisation
82 164 (Last-8) 24 Hour Totalized Volume at R Sm3 0 --
Address Def.
Parameter R/W Min Max
RS=1 RS=2 Unit
Std. Cond.
(Last-8) 24 Hour Totalized Volume at
83 166 R m3 0 --
Act. Cond.
84 168 (Last-8) 24 Hour Totalized Mass R kg 0 --
Start Time for (Last-8) 24 Hour
85 170 R HH,MMSS 0,0000 23,5959
Totalisation
(Last-9) 24 Hour Totalized Volume at
86 172 R Sm3 0 --
Std. Cond.
(Last-9) 24 Hour Totalized Volume at
87 174 R m3 0 --
Act. Cond.
88 176 (Last-9) 24 Hour Totalized Mass R kg 0 --
Start Time for (Last-9) 24 Hour
89 178 R HH,MMSS 0,0000 23,5959
Totalisation
(Last-10) 24 Hour Totalized Volume
90 180 R Sm3 0 --
at Std. Cond.
(Last-10) 24 Hour Totalized Volume
91 182 R m3 0 --
at Act. Cond.
92 184 (Last-10) 24 Hour Totalized Mass R kg 0 --
Start Time for (Last-10) 24 Hour
93 186 R HH,MMSS 0,0000 23,5959
Totalisation
Address Def.
Parameter R/W Optional Settings
RS=1 RS=2 Value
Unit – Velocity
100 200 R 1 (m/s) 2 (ft/s)
(Gas Flow and Sound)
101 202 Unit – Volume R 1 (m3) 2 (MMCF)
Unit – Volume Flow
102 204 R 1 (m3/h) 2 (MMCFD)
Rate
103 206 Unit – Mass R 1 (kg) 2 (lbs)
Unit – Mass Flow
104 208 R 1 (kg/h) 2 (lbs/h)
Rate
105 210 Unit – Pressure R 1 (bar A) 2 (kPa A) 3 (psi A) 4 (kg/cm2 A)
106 212 Unit – Temperature R 1 (°C) 2 (°F)
NOTE:
Not all register parameters listed in Section 4.3.7 and 4.3.8 may be available. They
are although listed in order to enable register mapping for future reading of these
parameters.
This is not according to the original Modbus standard [1] which only defines 16 bit
wide integer registers.
To access register values in one of the FGM 160 Modbus registers, one of the following
methods can be used:
Examples:
1) “Register Size” = 32 bits. Read two (32 bits) registers starting at addr. 12
(000Chex):
Request:
Modbus Slave Function Data Data No. of No. of Check Modbus
ASCII address code Start Start Regs. Regs. Sum ASCII only
only reg. reg. (MSB) (LSB)
(MSB) (LSB)
: E0 03 00 0C 00 02 XX <CR><LF>
Reply:
Modbus Slave Function Byte Data1 Data1 Data1 Data1 Data2 Data2 Data2 Data2 Check Modbus
ASCII addr. code count (MSB) (LSB) (MSB) (LSB) sum ASCII
only only
: E0 03 08 42 F7 66 66 40 10 A3 D7 XX <CR>
<LF>
2) “Register Size” = 16 bits. Read one (32 bits) register at addr. 12 (000Chex):
Request:
Modbus Slave Function Data Data No. of No. of Check Modbus
ASCII address code Start Start Regs. Regs. Sum ASCII only
only reg. reg. (MSB) (LSB)
(MSB) (LSB)
: E0 03 00 0C 00 02 XX <CR><LF>
Reply:
Modbus Slave Function Byte Data1 Data1 Data1 Data1 Check Modbus
ASCII addr. code count (MSB) (LSB) sum ASCII
only only
: E0 03 04 42 F7 66 66 XX <CR><LF>
For addresses and 16 bits data, the Modbus standard [1] defines a “big-Endian”
representation. This means that when a numerical quantity larger than a single byte is
transmitted, the most significant byte is sent first.
As there are no standard definitions regarding byte ordering for transmission of 32 bit
floating point values, the FGM 160 can be configured to handle different byte orders.
The FGM 160 can be configured for the following byte orders:
- DCBA (Most Significant Byte first, then Least Significant Byte, default config.)
- ABCD (LSB first, then MSB)
- CDAB (Most Significant Word first, then LSWord)
- BADC (Least Significant Word first, then MSWord, byte swapped)
The examples on previous page are shown with DCBA byte ordering (MSB first), which
is the default configuration for FGM 160.
In RTU mode, this value is the same as the actual count of bytes in the data section of
the message.
In ASCII mode, this value is one-half of the actual count of ASCII characters or bytes
in the data section of the message.
This is sufficient if the DCS system treats the FGM 160 Modbus registers as 32 bits
registers (“Daniel Option”, “Register Size” = 32 bits).
But if the DCS system treats the FGM 160 Modbus registers as 16 bits registers
(“Register Size” = 16 bits, Modicon Option), this may lead to a register overlap
problem internal in the DCS memory. The reason for this is that each 32 bits register
in FGM 160, will be read as two consecutive 16 bits registers by the DCS system, and
therefore occupy twice as many addresses internal in the DCS system as in the FGM
160 register map.
One way around this problem is to configure the FGM 160 to have all Modbus register
addresses spaced by two. This can be done by configuring the FGM 160 for: “Register
spacing” = 2 (RS=2, ref. Tables in section 4.3).
If the “Register spacing” is set to 2, the correct Modbus addresses can be obtained
from column “RS=2” in the register address map, section 4.3.
5. Number Representation
5.1 Single Precision Floating-Point Format
All Modbus register values in the FGM 160 are represented as 32-bit floating-point
values according to the IEEE 754 format.
Example:
or
41 A0 00 00 Hex
----------------------
6. Examples
6.1 Function Code 3, Read registers
Example: Read two (32 bits) registers starting at addr. 1010 (03F2hex):
Request:
Modbus Slave Function Data Data No. of No. of Check Modbus
ASCII address code Start Start Regs. Regs. Sum ASCII only
only reg. reg. (MSB) (LSB)
(MSB) (LSB)
: E0 03 03 F2 00 02 XX <CR><LF>
Reply:
Modbus Slave Function Byte Data1 Data1 Data1 Data1 Data2 Data2 Data2 Data2 Check M o d b u s
ASCII addr. code count (MSB) (LSB) (MSB) (LSB) sum ASCII
only only
: E0 03 08 00 00 00 00 41 20 00 00 XX <CR><LF>
Request:
Modbus Slave Function Start reg. Start reg. No. of Regs. No. of Regs. Byte count Data Data Data Data Chk. Modbus
ASCII addr. code (MSB) (LSB) (MSB) (LSB) (MSB) (LSB) sum ASCII
only only
: E0 10 04 07 00 01 04 41 20 00 00 XX <CR><
LF>
Reply:
Modbus Slave Function Start reg. Start reg. No. of Regs. No. of Regs. Chk. Modbus
ASCII addr. code (MSB) (LSB) (MSB) (LSB) sum ASCII
only only
: E0 10 04 07 00 01 XX <CR><LF>
Request:
Modbus Slave Function Sub-func. Sub-func. Test Data Test Data Check Modbus
ASCII address code code code (MSB) (LSB) Sum ASCII only
only (MSB) (LSB)
: E0 08 00 00 00 AA XX <CR><LF>
Reply:
Modbus Slave Function Sub-func. Sub-func. Test Data Test Data Check Modbus
ASCII address code code code (MSB) (LSB) Sum ASCII only
only (MSB) (LSB)
: E0 08 00 00 00 AA XX <CR><LF>
7. Exception responses
Different exception responses are implemented in the FGM 160. Some of these
exceptions will not occur under normal operation, but the error codes can be useful in
a development phase when new software is tested out. In exception response
messages, the Modbus slave (FGM 160) sets the MSBit of the Function Code to 1. This
makes the Function Code value in an exception response exactly 80hex higher than the
value would be for a normal response.
If the FGM 160 receives a request, but detects a communication error (parity, LRC,
CRC etc.), no response is returned. The DCS system will then eventually process a
timeout condition.
*)
: It specifically does NOT mean that a data item submitted for storage in a register
has a value outside the expectation (valid data range) of the application program,
since the Modbus protocol is unaware of the significance of any particular value of
any particular register.
Request:
Modbus Sl ave Function D a t a D a t a No. of No. of Check Modbus
ASCII address code Start reg. Start reg. Regs. Regs. Sum ASCII only
only (MSB) (LSB) (MSB) (LSB)
: E0 03 3A 98 00 02 XX <CR><LF>
Reply:
Modbus Slave Function Exception code Check Modbus
ASCII address code Sum ASCII only
only
: E0 83 02 XX <CR><LF>
8. Physical Layer
The Modbus electrical interface at FGM 160 is in accordance with EIA/TIA-485 (also
known as RS485 standard). This standard allows point to point and multipoint
systems, in a “two-wire” or “four-wire” configuration.
As the RS422 interface require a dedicated pair of wires for each signal, a transmit
pair and a receive pair, this compatibility is only applicable in four-wire configurations.
Four-wire systems often use an RS422 master (the driver is always enabled) and
RS485 slaves to reduce system complexity.
In four-wire configuration, the FGM 160 accepts an RS422 master (DCS system).
To avoid conflicts on the communication line, only one driver is allowed to transmit on
the line at any time.
To avoid conflicts on the communication line in “Multipoint” systems, only one driver is
allowed to transmit on the line at any time. “Multipoint“ system is defined as system
with more than one slave device driver(i.e. systems with one master and two or more
slaves).
The 4-W cabling must cross the two pairs of the bus between the master (DCS) and
the slave (FGM 160). That means that the Tx lines from the master must be
connected to the Rx terminals of the slave (FGM 160), and vice versa.
A 2-wire system must use a balanced pair and a third conductor for the Common
(signal GND).
An optionally 4-wire system must use two balanced pair and a third conductor for the
Common (signal GND).
Wire Gauge:
Wire gauge must be chosen sufficiently wide to permit the chosen combination of
baud rate and cable length. AWG24 (0.22 mm2) is normally sufficient.
Characteristic Impedance:
A value higher than 100 Ω may be preferred, especially for 19200 and higher baud
rates. Recommended characteristic impedance is: 120 Ω.
Cable length:
The end to end length of the Modbus communication cable must be limited.
The maximum length depends on the baud rate, the cable (Gauge, Capacitance or
Characteristic Impedance), the number of loads on the daisy chain, and the network
configuration (2-wire or 4-wire).
For a maximum 9600 Baud Rate and AWG26 (or wider) gauge, the maximum length is
app. 1000m. (AWG26 = app. 0.14 mm2)
Grounding:
The “Common” conductor (signal GND) must be connected directly to protective
ground, preferably at one point only for the entire bus. Generally this point is close to
the master device (DCS system).
Line termination:
Line terminations may be required for high baud rates and long distance.
If line terminations are required, termination resistors should be placed only at the
extreme ends of the communication line(s).
The value of the termination resistors should match the characteristic impedance of
the communication line. Typically value is: 120 Ω (should not be < 90 Ω).
Line Polarization:
The FGM 160 does not need any line polarization resistors (pull–up/pull-down
resistors).
The RS485 receiver (DCS Modbus receiver) at FGM 160, feature fail-safe circuitry
which guarantees a logic-high receiver output when the receiver inputs are open or
shorted. This means that the receiver output will be a logic high (passive level) if all
transmitters on a transmission line are disabled (high impedance).
Indication
State Description
(Color)
Comm. LED
Communication Switched ON during frame reception or sending.
(Green)
Power LED
Device status Switched ON: device powered
(Green)
Screw terminals are used for Modbus RS485 / RS422 connections in the FGM 160.
Figure 70 4-wire RS 485 interface between the FGM 160 and the DCS system.
Figure 71 2-wire RS 485 interface between the FGM 160 and the DCS system.
- The “DCS - R-“ terminal and the “DCS - T-“ terminal shall be wired together.
- The “DCS - R+“ terminal and the “DCS - T+“ terminal shall be wired together.
9. References
2. Modbus over serial line, Specification and Implementation Guide V1.02, (Dec. 20,
2006).
4. B&B electronics, Technical Article #11, Cable Selection for RS-422 and RS-485
systems, (January 1999).
1. Purpose .....................................................................................................151
2. Abbreviations/Definitions .............................................................................151
2.1 Abbreviations:........................................................................................................................ 151
2.2 Definitions: ............................................................................................................................ 151
3. General Information ....................................................................................151
3.1 HART Physical Layer ............................................................................................................... 151
3.1.1 Multidrop Operation ..................................................................................................... 151
3.1.2 Connection Loop ............................................................................................................ 151
3.1.2.1 Load Resistor .............................................................................................................. 151
3.1.2.2 Cabling ........................................................................................................................ 151
3.1.2.3 Signal Attenuation and Distortion .............................................................................. 152
3.2 HART Data Link Layer............................................................................................................. 152
3.2.1.1 Burst Mode ................................................................................................................. 152
3.2.1.2 Multimaster Operation............................................................................................... 152
3.2.1.3 Data Throughput ........................................................................................................ 152
3.2.1.4 Character Coding ........................................................................................................ 153
3.3 HART Commands (Application Layer).................................................................................... 153
3.4 HART Device Drivers .............................................................................................................. 153
3.4.1 Device Description (DD)................................................................................................. 153
3.4.2 Device Type Manager (DTM) ......................................................................................... 153
4. FGM 160 HART Functionality .........................................................................154
4.1 HART Output Channel............................................................................................................ 154
4.2 HART Compliance .................................................................................................................. 154
4.3 Device Drivers ........................................................................................................................ 154
4.4 Supported HART Commands ................................................................................................. 155
4.5 HART Poll Address ................................................................................................................. 155
4.6 Multidrop Mode .................................................................................................................... 155
4.7 Burst Mode ............................................................................................................................ 155
4.8 HART Output Parameters ...................................................................................................... 156
4.8.1 HART Variable Unit Codes ............................................................................................. 157
4.9 HART Interface Connection ................................................................................................... 157
4.9.1 Active Output (Loop is Powered from FGM 160) .......................................................... 157
4.9.2 Passive Output (Loop is Powered from HART Master/DCS System) ............................. 159
4.9.3 Multidrop Connections .................................................................................................. 160
4.9.4 Galvanic Isolation........................................................................................................... 160
4.9.5 Grounding ...................................................................................................................... 161
4.9.6 Load / Loop Voltage Limitations .................................................................................... 161
4.9.6.1 Active Output Configuration ...................................................................................... 161
4.9.6.2 Passive Output Configuration ..................................................................................... 161
4.9.6.3 Selection Criteria of Load Resistor Value ................................................................... 162
1. Purpose
This document describes the communication interface for the HART output channel of
the Fluenta Flare Gas Meter, FGM 160.
2. Abbreviations/Definitions
2.1 Abbreviations:
FGM Flare Gas Meter
HART Highway Addressable Remote Transducer
2.2 Definitions:
HART A widely used extension to the 4-20 mA analogue signal used in sensor
networks. HART superimposes a 1,200 bits/second digital signal onto the
line that provides bi-directional communications with intelligent devices.
3. General Information
3.1 HART Physical Layer
HART uses a frequency-shift keying to superimpose digital communication at 1200
baud on to the 4 to 20 mA current loop. Two different frequencies are used to
represent binary 1 and 0 (1200 Hz and 2200 Hz respectively).
The average value of the superimposed HART signal is zero, so no d.c. component is
added to the existing 4 to 20 mA signal. Thus the analogue 4 to 20 mA signal may be
used in addition to the HART communication.
3.1.2.2 Cabling
The field wiring of a HART system should use a screened twisted pair cable.
Preferably individually-screened twisted pairs should be used to avoid possible
crosstalk between pairs.
Since the maximum length of the HART communication line (limited by the RC time
constant) is much smaller than the wavelength of the HART signal (app. 120 km), the
practical HART networks don’t act like transmission lines and there is no need for
impedance matched cables or terminations.
The loop resistance mainly consists of the loop resistor, but the cable resistance will
also give a contribution. For long cable lengths, the loop capacitance consists mainly
of the cable capacitance. Device capacitance will also contribute a bit, especially in
multidrop networks with several devices connected in parallel. HART specifications
recommend 5000 pF as a maximum value for device shunt capacitance.
In burst mode more than three messages can be transmitted per second.
Example: in a multidrop network with 4 devices, the latency will be app. 2 seconds
(i.e. the update rate for each device is app. 2 sec.).
“Universal commands” provide functions which are implemented in all HART compliant
field devices.
The DD identifies which common practice commands are supported as well as the
format and structure of all device-specific commands.
FDT (Field Device Tool) is an interface specification that standardizes the data
exchange between field devices and the system level (FDT frame application).
FDT frame applications can be device configuration tools, control systems, operator
consoles or asset management tools etc.
FDT is communication independent and can be used with any communication protocol
(e.g. HART, Modbus, Profibus, Foundation Fieldbus, etc.).
An appropriate DTM for every instrument of every supplier is not yet available. If no
specific DTM exists for a HART-capable field device, a generic HART DTM can be used.
The universal and common-practice commands based on the HART specification that
are used by most HART devices on the market are supported by the generic DTM.
Generic HART DTM is available from various companies (e.g. ICS GmbH).
The HART output channel can be configured as a passive output (external loop power)
or as an active output (powered from FGM 160).
NOTE:
The FGM 160 does not support any HART write commands and it is therefore not
possible to configure the device via the HART interface.
For configuration of the FGM 160, the FGM 160 Operator & Service Console must be
used. This software communicates with the FGM 160 through the dedicated RS-485
service port.
The default HART poll address for the FGM 160 is:
If the HART poll address is set to a value other than 0, the analogue current loop
signal is set to a fixed value of 4 mA. The device is then parked and enabled for
multidrop operation.
Any of these parameters can be selected for HART Primary variable (PV), Secondary
variable (SV), Third variable (TV) and Fourth variable (FV).
The selected parameters will be available for read-out through HART command 1 (PV)
and HART command 3 (PV, SV, TV and FV).
For configuration of the HART output parameters, the FGM 160 Operator & Service
Console must be used.
Notes:
1)
: Data from HART Transmitters is only applicable for FGM 160 systems configured
for HART Pressure and Temperature transmitters.
2)
: Data from HART Transmitter 2 is only applicable for FGM 160 systems
configured for double HART transmitters.
*)
: Optional units:
Table 6 – HART output parameter, optional units.
Parameter Optional units
MMCFD (Million Cubic Foot per Day),
Volume flowrate
MMSCFD (Million Standard Cubic Foot per Day)
Mass flowrate lbs/h
Velocity ft/s
Pressure kPa A, psi A, kg/cm2 Abs
Temperature °F
Acc./totalized volume MMCF, MMSCF
Acc./totalized mass lbs
For configuration of HART output parameters units, the FGM 160 Operator &
Service Console must be used.
All HART variable values will be transmitted as floating-point numbers, 32-bit single
precision (IEEE 754), according to HART specification HCF_SPEC-127.
÷ Power
Active output
Passive output
connections
connections
+ supply
The HART output terminals (as well as the other current loop outputs) are galvanic
isolated from the rest of the FGM 160 electronics.
However, the individual current loop outputs are not isolated with regards to each
other. (i.e. the HART output terminals are not isolated from the other current loop
outputs of the FGM 160).
4.9.5 Grounding
To prevent interference by external signals, it is important to ground the system
properly.
The cable screen must be connected to ground at one point only. This single ground
point will normally be at or near the primary master (for example, the control
system). The screen is left open at the other end (normally field instrument end) to
avoid the conduction of ground currents.
The signal loop should be grounded at one point or may be ungrounded (floating) if
electrical noise is minimal. If the signal loop is grounded, the negative signal wire
should be connected to ground, preferably at the same point as the cable screen.
1200.0
1100.0
1000.0
900.0
Load resistor [Ω]
800.0
700.0
HART operating range
600.0
500.0
400.0
300.0
200.0
5 7.6 10 15 20 25 30 32.6 35 40 45 50
Loop voltage [V]
4.9.7 Cabling
Low capacitance, individually screened, twisted pair cable with min. 0.5 mm2 cross
section (AWG 20) is recommended.
For shorter distances, 0.2 mm2 (AWG 24) twisted pair with common screen can be
used.
A low loop resistor value will help to increase the max. loop length (however, the
lower limit in HART specification is 230 Ω).
Multidrop operation reduces the possible cable length, since the capacitance of the
field devices increases the total C (and the RC time constant).
Note:
The total loop resistance consists of load resistor + cable resistance (both conductors
in series).
The cable capacitance is the capacitance measured from one conductor to all others
and screen (not between the two conductors of a pair, as commonly quoted).
1000
500
0
230 330 430 530 630 730 830 930 1030 1130
Load resistor [Ω]
Cable parameters used in Figure 77: RFOU(i) 0.75 mm2: 115 pF/m, 25 Ω/km
IYOI(c) 0.2 mm2: 90 pF/m, 95 Ω/km
Belden 3105A 0.35 mm2: 66 pF/m, 49 Ω/km
5. REFERENCES
[1] HART Field Communication Protocol, A Technical Overview. (Second Edition).
Romilly Bowden, February 2002.
[2] About HART, By Analog Services, Inc., Part 1: Preliminaries (rev. 2-1-01)
[3] About HART, By Analog Services, Inc., Part 2: Practical Stuff (rev. 8-9-99)
[4] About HART, By Analog Services, Inc., Part 3: Ponderous Stuff (rev. 8-9-99)
1. Purpose
The purpose of this document is to give a detailed description of how the Operator &
Service Console (O&SC) operates. This document will only cover the section related to
the Operator interface, as the Service section applies to Fluenta support personnel
only. The interface between the FGM 160 and the O&SC will be described, with local
and remote operation. Further, the menu and windows based O&SC software will be
outlined with detailed description of each program window.
2. Abbreviations/Definitions
2.1 Abbreviations:
FGM Flare Gas Meter
O&SC Operator & Service Console
3. General
3.1 Interface Between FGM 160 and O&SC
The O&SC can be interfaced to the FGM 160 either by 2- or 4-wire RS 485 or 4-wire
RS 422. The communication protocol setup is fixed at:
Baudrate: 38400
Data bits: 8
Stop bits: 2
Parity: None
Protocol: Modbus RTU
Figure 1 shows the Fluenta AS Flare Gas Meter (FGM 160) terminals. The only
terminals that are of interest in this procedure are terminals 16-20, as they are the
terminals that provide a connection to the operator console. There are two possible
connections that can be made to these terminals, either a two or four wire RS485
cable. These connections are explained in detail in the following sections.
To avoid conflicts on the communication line, only one driver is allowed to transmit on
the line at any time.
To avoid conflicts on the communication line in “Multipoint” systems, only one driver is
allowed to transmit on the line at any time. “Multipoint“ system is defined as system
with more than one slave device driver (i.e. systems with one master and two or more
slaves).
The 4-W cabling must cross the two pairs of the bus between the master (O&SC) and
the slave (FGM 160). That means that the Tx lines from the master must be
connected to the Rx terminals of the slave (FGM 160), and vice versa.
A 2-wire system must use a balanced pair and a third conductor for the Common
(signal GND).
An optionally 4-wire system must use two balanced pair and a third conductor for the
Common (signal GND).
Wire Gauge:
Wire gauge must be chosen sufficiently wide to permit the chosen combination of
baud rate and cable length. AWG24 (0.22 mm2) is normally sufficient.
Cable length:
The end to end length of the Modbus communication cable must be limited.
The maximum length depends on the baud rate, the cable (Gauge, Capacitance or
Characteristic Impedance), the number of loads on the daisy chain, and the network
configuration (2-wire or 4-wire).
Grounding:
The “Common” conductor (signal GND) must be connected directly to protective
ground, preferably at one point only for the entire bus. Generally this point is close to
the master device (DCS system).
Line termination:
Line terminations may be required for high baud rates and long distance.
If line terminations are required, termination resistors should be placed only at the
extreme ends of the communication line(s).
The line termination resistors shall be selected according to the cables characteristic
impedance; typical 120 Ω. Non-terminated or wrong terminated cables may cause
severe communication problems.
Line Polarization:
The FGM 160 does not need any line polarization resistors (pull–up/pull-down
resistors).
The RS485 receiver (O&SC) at FGM 160, feature fail-safe circuitry which guarantees a
logic-high receiver output when the receiver inputs are open or shorted. This means
that the receiver output will be a logic high (passive level) if all transmitters on a
transmission line are disabled (high impedance).
Figure 80 4-wire RS 485 interface between the FGM 160 and the O&SC.
The connection below illustrates the 2-wire RS485 connection. Usually either an
RS485 to USB or an RS485 to RS232 converter is required to interface to the
computer with the Operator & Service Console software installed.
Figure 81 2-wire RS 485 interface between the FGM 160 and the O&SC, with
jumpers between T- and R-, and between T+ and R+.
- The “Serv. Port - R-“ terminal and the “Serv. Port - T-“ terminal shall be wired
together.
- The “Serv. Port - R+“ terminal and the “Serv. Port - T+“ terminal shall be wired
together.
If remote control of the FGM 160 is requested, a RS485 - TCP/IP converter can be
used in order to access the computer with the O&SC software installed.
operator will have full access control of the HOST computer, allowing only authorized
users to access the local (HOST) computer.
By using the Remote Control software, the remote computer (the GUEST) will take
control of the local computer (the HOST). Thus, the GUEST will run the O&SC as if the
software was installed at the GUEST computer.
O&SC
O&SC
Remote
Control
FGM 160 HOST Remote
Control
RS 485
GUEST
RS 485 - TCP/IP
FGM 160 converter O&SC
Figure 83 Remote operation of the O&SC, with two different configurations; either
by RS485 / TCP/IP interface, or through Remote Control software.
Figure 84 O&SC general layout, with Graph Bar, Live Data and Log windows.
Figure 85 The O&SC menus overview, with the “File”, “Edit”, “View”, “Polling
mode”, “Tools” and “Help” items outlined.
Figure 86 The Live Data window is activated through the View → Live data menu.
The Live Data window is a read-only information window, with
information on the current system and updated (live) process data.
Ø Mass Flow
Ø Volume Flow act. Vol. – The volume flow at actual (line) conditions
Ø Volume Flow std. Vol. – The volume flow at standard conditions
Ø Gas Flow Velocity
Ø Pressure
Ø Temperature
Ø Density
Ø Sound Velocity
Ø CWUpAve – Average transit time in the Upstream direction
If it is desired to have less than four parameters shown on the graph, select the
“Unused” option. The legend at the top of the Graph Bar window shows which items
are currently being displayed.
Figure 87 The Graph Bar window, with up to four different process parameters
displayed as graph data.
By pressing the button the Graph Config window opens. This allows
the operator to configure the look of the graph as well as the scale. The trend
diagram area allows the operator to choose the Y Scale and the Time Scale. The Y
Scale can either be set to automatic by checking the checkbox next to the field
Autoscale and setting the minimum range, or stated explicitly by entering the
minimum and maximum values for the parameters. The Bar Plot area allows the
operator to set the maximum value, the warning, and whether to plot Mass Flow or
Volume Flow.
Figure 88 The Graph Bar - Graph Config window. Each graph bar can be
individually configured with either autoscale or defined minimum and
maximum range. If autoscale is selected, a minimum range (span) can
be set.
3.6 Log
3.6.1 Alarm Log
By selecting the Log option from the View menu item from the Main Window. The
window comes up showing the Log Main Page tab which lists the alarms that have
occurred. There are two options when it comes to copying the Alarm Log. The first is
to copy it to the clipboard. This enables the operator to paste the data wherever
necessary. The second is to copy the alarm log to a file. This saves the Alarm Log as
a text file to a specified location. The last choice in this tab is to clear the alarm log.
The Change Descriptions button opens the System Description dialog box, ref.
Figure 92. This allows the operator to change the information shown in the Live Data
window shown in Section 3.4.
The Real Time Clock section allows the operator to set or get the clock readings from
the flow computer. The Synch with PC button synchronizes the flow computer clock
with the clock in the PC running the Operator and Service Console software.
The Update button updates (refreshes) the real time clock values based on current
information locally on the O&SC computer. The Calculation Parameters section
allows the operator to set the Flow Velocity Threshold(cut-off), the reference
temperature for standard conditions, and the reference pressure for standard
conditions. The flow velocity threshold is the low flow cut-off limit that can be
implemented upon operator request. Flow values below the cut-off limit will be set to
zero. The reference temperature for standard conditions is default 15.0 °C, and the
reference pressure for standard conditions is default 1.01325 barA.
The Units section allows the operator to switch from SI units to English units. This
changes the units for the DCS Modbus and HART register values.
The Modbus Parameters DCS port section allows the operator to set up the
communication parameters.
The Get Config to Clip Board copies the configurations file to the clip board so that
it can be pasted into an existing document (e.g. configuration file template). The
button Get Config to File saves the system configuration to a text file. The dialog
boxes in Figure 93 illustrate how this is done.
Figure 95 The Config - Input signals configuration window, with HART interface
selected for the pressure and temperature input signals.
The Pressure Processing drop down selection box allows the user to switch between
the HART and the Current Loop as sources for the pressure input.
The Temperature Processing drop down selection box allows the user to switch
between the HART, Current Loop, and RTD as sources for temperature input. The RTD
is integrated in the ultrasonic sensors, and will measure the process temperature
through the ultrasonic sensor walls.
The Current Loop Calibration Pressure and Temperature groups allow the operator to
set the offset and scale for the pressure and temperature inputs, ref. Figure 96.
When selecting the HART interface for the pressure and temperature input signals, the
Input Config must be set to HART. Further the check boxes Enable HART
Temperature/Pressure must be selected (checked), ref. Figure 95.
When selecting the 4-20 mA current loop interface for the pressure and temperature
input signals, the check boxes for Enable CurrentLoop Temperature/Pressure must
also be selected (checked), ref. Figure 96. Enable HART Temperature/Pressure should
NOT be checked in this case.
Figure 96 The Config - Input signals configuration window, with 4-20 mA current
loop interface selected for the pressure and temperature input signals.
The Current Loop Range: Temperature & Pressure groups allow the operator to set the
4-20mA range to the corresponding temperatures and pressures, respectively. It is
important that these ranges match the output ranges of the transmitters. If not, the
72.120.606/D Page 183 of 211
Maintenance Procedure
readings of the FGM 160 will not be correct. If HART interface is selected, the settings
for Current Loop Range: Temperature & Pressure will have no effect, as the pressure
and temperature values will be transmitted as digital values.
The 4-20 mA input channels can be calibrated using e.g. a loop calibrator. By using a
first degree curve fitting approach, the offset and scale values can be obtained. The 4-
20 mA input channels of the FGM 160 are calibrated at the Fluenta AS workshop,
ensuring that no calibration should be required during installation and commissioning,
ref. Figure 96.
If no direct interface from the pressure and temperature transmitters has been
established, these process values can be transmitted from the DCS system to the FGM
160 through the DCS Modbus interface. The DCS system must then, as Modbus
master, supply pressure and temperature values to the FGM 160 at regular intervals.
In order to enable the FGM 160 to read pressure and temperature values through the
DCS Modbus interface, the Get Pressure/Temperature from Modbus check boxes must
be selected (checked), ref. Figure 97.
Note:The check boxes are NOT exclusive. Thus, selecting one check box does not
automatically deselect the alternative option check box. Make sure that options
that are not selected, are deselected (NOT checked).
Figure 97 The Config - Input signals configuration window, with DCS Modbus
interface selected for the pressure and temperature input signals.
For each of the current loops enabled, the corresponding Current loop X (X being the
number of the current loop 1- 6) must be configured. The drop down box allows the
user to select which parameter will be transmitted at the output. The choices are Std.
Volume flow, Actual Volume flow, Mass flow, Density, Molecular weight, Alarm,
Temperature, Pressure, and Testvalue, ref. Figure 99. The desired parameter must be
selected and the corresponding configuration values to the right must be entered.
If the Enable HART check box is selected, the HART Output (Slave) Config group must
be configured, ref. Figure 98. The Poll address must be entered, and up to four
parameters can be selected. These parameters can be any combination of Flow Std,
Flow Act, Flow Mass, Flow Velocity, Sound Velocity, Density, Pressure and
Temperature.
Figure 98 The Config - Output signal configuration window, with the HART Output
(Slave) Config box outlined. The Poll Address must be selected (1 – 15),
Figure 99 The Config - Output signal configuration window, with the parameters
available at the 4-20 mA current loop outputs outlined.
1. The Maximum and Minimum which are the upper and lower limits of the sound
velocity before an alarm is generated.
2. The Maximum Sound Velocity jump regarded as an expected process variation.
3. The Historical VOS weight factor which is used in calculating the Historical VOS.
1. The Maximum and Minimum which are the upper and lower limits of the flow
velocity before an alarm is generated.
2. The Maximum Change which is the maximum difference between two
consecutive readings before an error is reported.
For the Temperature and Pressure, the Maximum and Minimum alarm values must be
specified. Input values outside the alarm range will generate an alarm.
Figure 100 The Config - Alarm Limits window, with specified Maximum and
Minimum values for Sound Velocity, Flow Velocity, Temperature and
Pressure.
Based on the specified transducer distance and the max/min values for Sound Velocity
and Flow Velocity, the Maximum and Minimum values for Time-of-Flight (TOF)
Downstream and Upstream are calculated. These values are used internally in the
FGM 160 in order to check the validity of the transit time measurements.
Further, the % used of the measured transit times for the flow calculations are
displayed. If all measured transit times are used for the flow calculations, the
numbers should be 100.0. Any erroneous measurements or outliers that are discarded
during the filtering process will reduce the number of % used.
In addition, the gas flow velocities can be viewed, both prior to flow profile
compensation (uncompensated) and after flow profile compensation. Thus, the “raw”
(uncompensated) axial gas flow velocity can be viewed, along with the average axial
gas flow velocity (compensated for flow profile).
Figure 101 The Transit Time Measurements window, with the Chirp and CW
measurements, the uncompensated and flow profile compensated flow
velocity and velocity of sound, and the % used transit time
measurements.
Figure 102 The Help About window, with information on the O&SC software
version.
7. MAINTENANCE INSTRUCTIONS
1. Purpose
The purpose of this procedure is to describe the necessary maintenance and
preventive maintenance for the Fluenta Flare Gas Meter, FGM 160.
2. Abbreviations/Definitions
2.1 Abbreviations:
FGM Flare Gas Meter
TFS Transducer Full Size
O&SC Operator & Service Console
2.2 Definitions:
N/A
3. General
The FGM 160 requires only minimum maintenance. It is a system with no mechanical
moving parts. Maintenance is carried out if an error is detected or suspected to have
occurred. In addition, Fluenta strongly recommends a periodical maintenance routine
to secure the operational uptime of the meter. Below checks are standard procedure.
Take contact with Fluenta Service&Support for more information or booking of
maintenance.
The instructions are given for each major component in the flare gas metering system
and the time periods between each activity is also specified.
4.1 Connectors
Check that all connectors in the EEx-e housing are properly connected and that there
is no corrosion or contamination on the terminals.
enclosure. Carefully remove the sunshield and put it in a safe place to ensure no
damage while working with the EEx-d enclosure, ref. Figure 103.
1) Use the universal opener tool shown below for loosening first only the black top
Ex-d part of the EEx-d enclosure by turning counterclockwise.
2) After inspection of the O-ring (126,67 x 2,62mm) and the threads, put copper
paste on the threads before carefully sliding the top part back in position.
3) Use the universal opener tool shown below for loosening now the pipe Ex-d part
(incl. top Ex-d) by turning the pipe counterclockwise.
4) Remove the electronics stack to inspect the O-ring (126,67 x 2,62mm) in the
bottom. Caution: ESD safety must be in place! Inspect also threads.
5) Re-mount the electronics stack.
6) Put copper paste on the threads before carefully sliding the pipe Ex-d part back
in position.
7) Re-install the sunshield in order to complete the operation.
Note: Should replacement of the O-rings be necessary the new O-rings (126,67 x
2,62mm) must be slightly expanded for optimal fitting.
Figure 103 FGM 160 with description of how to dismount the Ex-d enclosure.
The EEx-d housing should under normal circumstances not be opened. However, if
required, the work should be performed in a work-shop in Safe Area or under good
weather conditions.
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Maintenance Procedure
Figure 104 FGM 160 WARNING label regarding opening the Ex-d enclosure when an
explosive gas atmosphere is present.
Check all meter functions and if any indications of malfunction, go through the Factory
Acceptance Test Procedure for FGM 160, Fluenta doc. no. 62.120.003. This should
preferably be carried out by Fluenta personnel, generally in collaboration with
personnel responsible for daily operation of the system.
In addition to the procedure already mentioned above, a reliable zero point check and
if required, adjustment for the different transmitted ultrasonic signals should be
carried out. Fluenta service personnel are making use of a portable, special designed
box for this purpose.
Different signals will also be analyzed by Fluenta personnel, using the Operator &
Service Console (O&SC) program. The O&SC displays important information of how
the system operates, and how to troubleshoot potential errors, as the signals can be
interpreted, compared and optimized if necessary.
Using experienced and qualified Fluenta personnel once a year to run a total system
functionality check is recommended as this will decrease the possibility for a system
malfunction and increase the system reliability.
RS485-TCP/IP
converter, or
Remote
Control
Software
Haz. Area Local Remote
Figure 105 Local and remote control of the FGM 160 Field Computer by using the Operator &
Service Console software.
· Make sure that all nuts and bolts between the transducer holder and the ball valve
and between the ball valve and the transducer unit are properly tightened.
· Check that the ball valves are open (not in contact with the transducers).
· Check that the nut (on fitting) at the end of the packing box is tight.
6. Cables
Inspect transducer cables and the FGM 160 cables for damages. Make sure that the
cables do not have any sharp bends and ensure that there is no contact between the
cables and sharp edges that can cause damages. Interfering equipment in the
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Maintenance Procedure
surroundings must be kept in a safe distance from the cables and the rest of the FGM
160 equipment.
7. Lubrication
Refer to 4.2.2 for parts that need lubrication as preventive maintenance.
8. References
N/A
9. DRAWINGS
Replacement for:
211
Total no. of pages:
Fluenta doc. Ref:
72.120.606/D
Page 211 of 211